Production of pile surface materials



Oct. 15, 194 H. A. WINTERMUTE PRODUCTION OF PILE SURFACE MATERIALS 2 Sheets-Sheet 1 Filed Sept. 24, 1956 Oct. 15,1940. H. A. WINTERMUTE" 2,218,445

PRODUCTION OF FILE sqRFAcE MATERIALS,

Filed Sept, 24, 1956 2 Shets-Sheet 2 Patented Oet. 15,1940

UNITED STATES PATENT OFFICE PRODUQTlfi 01 PM SURFACE tram A.Wintennute, Plainfield. n.1, assignor, by mesne assignments, to Behr-Manning Corporation, a corporation of Massachusetts Application September 24, 1936, semi No. 102,395

2Ciaims.

This invention relates to the production of pilesurfaced material andis particularly directed to a process and apparatus for the utilization of the combined effects of electrical and mechanical I forces to produce artificially piled surfaces having a high degree of uniformity of appearance and formity may be obtained by the method of the invention which comprises depositing pile-forming material upon an adhesive-surfaced backing,

and subjecting the deposited pile material, before 28 the adhesive is fully hardened, .to a shaking or vibratory action while bringing within the orienting influence of a strong electric field, either alternating or unidirectional.

This method makes possible the production of so a thicker pile than can be obtained by mechanical methods alone, while for a given thickness of pile the adherence of the fibers is greatly increased and the time required for the production of the pile is substantially shortened. The fibers 85 stand more nearly normal to the surface, are

more uniformly distributed, and are more uniformly oriented than when mechanical forces alone are used. The method of the invention is far less sensitive to air conditions, such as tem- 40 perature and humidity, than methods involving the use of electric fields alone for depositing and orienting the fibers. Moreover, the fibers are more firmly fixed in the adhesive surface by the method of the invention than by the use of either 45 the electric field or mechanical forces alone.

Various modifications of the method have been found to be advantageous for certain purposes. For example, a more durable bonding of the fibers may be obtained by subjecting the piled material 50 to a subsequent conditioning whereby the adhesive is somewhat softened, for example, by

heating. The further treatment may also advantageously include subjecting the material while in the conditioned state to mechanical vi- 65 bration. The conditioning of 'the material by softening the adhesive after the depositing of the fibers, causes the fibers to be more firmly gripped by the adhesive and this effect is furtheredby a concomitant vibration. 1

The method and apparatus of the invention 5 will be more particularly described with reference to the illustrative embodiments shown in the accompanying drawings in which Fig. 1 illustrates one form of method and apparatus embodying the principles of the invention; and Fig. 2 represents a modified form of the invention.

In Fig. 1, ill represents a high potential electrode and II a grounded electrode. The elecl5 trodes are supplied with unidirectional high potential current by means of mechanical rectifier i2. Electrode il comprises a plurality of fixed bars 2|, preferably curved on their upper sides, and a number of movable striking bars 22 carrled on rocker arm l3. Arm I3 is rocked about pivot It by means of lever arm 23 and armature 24 of electromagnets [5 which are energized in alternation by means of reversing switches it operated by extension 25 on lever arm 23. 25

A web A, for example, of fabric material, is passed over roller II, where it is coated with adhesive from container It by means of dip roll l9. Suitable fibrous material, such as rayon flock,

is strewn in predetermined amount on the adhesive-coated surface of the web by means of the rotating sifter 20. The web carrying the fibers on its adhesive-coated surface is then passed between electrodes 10 and II, adjacent lower electrode II where it is subjected to the combined efects of the strong electrical field between the electrodes and the vibration of rapper II. The combined action of the electrical and mechanical forces cause the flack to be worked endwise into the adhesive. The electrical field tends to orient the fibers in a direction perpendicular to the field and at the same time cooperates with the vibration in tending to force the flock further into the adhesive, while the vibration tends to make the fibers more responsive to the orienting efiect of the electrical field.

In Fig. 2, 30 is a high potential electrode energized as shown in connection with electrode II in Fig. 1, while 3| is-a grounded electrode provided with vibrator mechanism, for example, of the 5 gripe shown in connection with electrode Ii in Web A is led from roll 32 under coater 33 which provides a coating of adhesive on the upper surface of the web, and then under sifter 34 which sprinkles a desired quantity of flock on the web. The web then passes between electrodes 30 and II, where it is subjected to the combined efiects of a high potential electrical field and mechanical vibration as in F18. 1.

The pile-surfaced web is then passed under a vibrator 35 which may be of the same type as shownin connection with electrode II in Fig. 1, where excessfiber is shaken on and 'falls into hopper 36. The web is then led into heater 31 wherein the adhesive is softened. While the adhesive is in the softened condition it is subjected to further vibration by vibrator 38 in order to more firmly position the fibers in the adhesive. The web is then subjected to conditions for finally indurating the adhesive, for example, by means of drier l9, and the finished material is rolled up on roll it.

The adhesive used in the practice of the invention should be sumciently viscous to avoid a tendency to pull oif or string in the electrical field, and also to prevent the fibers laid thereon from penetrating too'far into the adhesive prior to passage into the electrical field. The adhesive may well be more viscous than when electrical forces alone are used for the deposition as the combination of mechanical and electrical forces will force the fibers into a more viscous adhesive.

The method and apparatus of the invention are particularly valuable for the deposition of fibers of short length and for operating under conditions such that the fibers have very low conductivity. The method is very flexible as to condi- 5 tions of operation, type and size of fiber, character of adhesive, nature of base material and the like and permits of a wide variation in these and other factors.

I claim:

1. A method of making pile surfaces comprising forming a mat of pile-forming fibers on an adhesive-coated surface and then subjecting the surface and the pile-forming fibers to the conjoint action of a strong electrical field and mechanical vibra- 15 tion and thereafter softening the adhesive temporarily and subjecting the material to mechanical vibration while the adhesive is in softened condition.

2. In the production of pile-surfaced materials by the deposition of pile-forming fibers upon an adhesive-coated surface, the improvement which comprises subjecting the adhesive having .pileforming fibers imbedded therein to softening conditions and mechanically vibrating the material while the adhesive is in softened condition.

HARRY A. WINTERMU'I'E. 

